Methods for forming dry floor components

Abstract

The present invention relates to a method of forming a dry floor assembly (200), the method comprising cleaning the upper layer (208) with methyl ethyl ketone, i.e., MEK (252), prior to bonding the upper layer (208) to the carbon core absorbent layer (206). The cleaning removes a release agent (208) from the upper layer. The method further comprises bonding the upper layer (208) to the carbon core absorbent layer (206) after the cleaning.

Description

Technical Field

[0001] Examples of this disclosure generally relate to methods for forming dry floor components (such as those that can be used in the lavatory of a vehicle). Background Technology

[0002] Commercial aircraft are used to transport passengers between various locations. During flight, especially on transoceanic or other long-haul flights, passengers are typically confined to certain areas of the aircraft (e.g., cabins). Various personnel (such as passengers, pilots, flight attendants, etc.) use certain interior parts of the aircraft during flight. For example, many people may use the lavatories within the cabins during flight.

[0003] As is understandable, the cleanliness of lavatories on aircraft may be compromised after each use. Passengers may be sensitive to the health risks posed by lavatories used frequently on aircraft. In fact, the likelihood of germs and bacteria accumulating in lavatories increases when personnel use them.

[0004] Aircraft lavatories are typically cleaned between flights. For example, maintenance or cleaning personnel board the aircraft on the ground before and / or after a flight to clean the lavatories. However, during a flight, although many people may actually use the lavatories, they are not usually cleaned. While flight crew members may be able to clean the lavatories, they are typically focused on other duties during the flight. Therefore, cleaning lavatories during or even between flights may not be a high priority for flight crew members.

[0005] In cases of repeated use, multiple sections of the washroom floor may be covered in liquid. Even after cleaning, the washroom floor may remain wet from cleaning fluids. A wet washroom floor can be unsettling for people, even if they know the floor is clean. That is, a wet floor can give the impression of unsanitary conditions. Furthermore, a wet floor can pose a safety hazard, as people may slip and fall on it.

[0006] Therefore, dry floor components have been developed. Examples of such dry floor components include U.S. Patent No. 10,065,740 (titled "Systems and Methods for Cleaning a Lavatory Floor") and U.S. Patent No. 10,982,439 (titled "Dry Floor LiquidDisposal System").

[0007] Known dry floor assemblies include a top hydrophobic layer bonded to a thick intermediate carbon wicking layer, which in turn is bonded to a perforated steel backing. The carbon wicking layer is configured to facilitate water distribution and meet flammability requirements. However, it has been found that over time, the top layer and steel backing can interfere with the carbon wicking layer's ability to allow water to pass through. For example, the wicking layer can be clogged by certain chemicals, thereby reducing its ability to effectively allow water to pass through. Summary of the Invention

[0008] There is a need for a method to form dry floor assemblies that reduces the likelihood of the wicking layer being contaminated by chemicals that would otherwise reduce its wicking and water permeability. Furthermore, there is a need for a dry floor assembly that maintains the wicking layer's ability to permeate water over time.

[0009] In view of these needs, certain examples of this disclosure provide a method for forming a dry floor assembly, the method comprising: cleaning the upper layer with methyl ethyl ketone (MEK) before bonding the upper layer to the carbon core layer, wherein the cleaning removes a release agent from the upper layer; and bonding the upper layer to the carbon core layer after the cleaning.

[0010] In at least one example, the cleaning involves rinsing the upper layer with MEK using one or more brushes.

[0011] In at least one example, the method further includes washing the upper layer with water or detergent after cleaning the upper layer with MEK. As another example, washing the upper layer with water or detergent includes washing the upper layer with water or detergent using one or more brushes. In at least one example, the method further includes rinsing the upper layer with water after cleaning the upper layer with MEK and washing it with water or detergent.

[0012] In at least one example, the method further includes pre-washing the carbon core layer with water before bonding the upper layer to the carbon core layer, wherein the pre-washing removes excess polyvinyl acetate (PVA) from the carbon core layer.

[0013] In at least one example, the method further includes applying a primer only to a first surface of the lower support layer, wherein a second surface opposite to the first surface is not primed; and bonding the first surface of the lower support layer to the carbon core absorption layer.

[0014] In at least one example, the lower support layer is made of steel. In at least one example, the upper layer comprises a urethane grid. Attached Figure Description

[0015] Figure 1A three-dimensional interior view of a washroom according to an example of this disclosure is shown.

[0016] Figure 2 An exploded perspective view of a dry floor assembly according to an example of this disclosure is shown.

[0017] Figure 3 A perspective top view of a dry floor assembly according to an example of this disclosure is shown.

[0018] Figure 4 A stereoscopic top view of the upper layer removed from the tool, according to an example of this disclosure, is shown.

[0019] Figure 5 A perspective top view is shown of the upper layer cleaned with methyl ethyl ketone (MEK) to initially remove the release agent, according to an example of this disclosure.

[0020] Figure 6 A perspective top view of the upper layer of MEK being cleaned to remove excess release agent and MEK, according to an example of this disclosure, is shown.

[0021] Figure 7 A top view of the lower support layer according to an example of the present invention is shown.

[0022] Figure 8 A bottom view of the lower support layer according to an example of the present invention is shown.

[0023] Figure 9 A flowchart illustrating a method for forming a dry floor assembly according to an example of this disclosure is shown.

[0024] Figure 10 A three-dimensional front view of an aircraft according to an example of this disclosure is shown.

[0025] Figure 11 A perspective top view of a dry floor assembly according to an example of this disclosure is shown.

[0026] Figure 12 A top view of an wicking layer according to an example of this disclosure is shown. Detailed Implementation

[0027] The foregoing summary of the invention and the following detailed description of certain examples will be better understood when read in conjunction with the accompanying drawings. As used herein, an element or step described in the singular and preceded by the words “a” or “an” should be understood to not necessarily exclude a plurality of elements or steps. Furthermore, the reference to “an example” is not intended to be construed as excluding the existence of additional examples that also include the referenced features. Moreover, unless expressly stated to the contrary, examples that “comprise” or “have” an element or plurality of elements having a particular condition may include additional elements that do not have that condition.

[0028] Certain examples of this disclosure provide a method for forming a dry floor assembly, the method comprising treating the grille prior to attaching it to a carbon core absorber layer. In at least one example, the treatment comprises cleaning the grille with methyl ethyl ketone (MEK) and washing the grille with water or soap and water prior to attaching the grille to the carbon core absorber layer. In at least one example, the method further comprises pre-washing the carbon core absorber layer, such as with water, prior to attaching the grille to the carbon core absorber layer to remove (i.e., remove all, substantially all, or a small portion) of the polyvinyl acetate (PVA). In at least one example, the method further comprises applying a primer only to one side of the steel support layer. The primer-coated side of the steel support layer is attached to the carbon core absorber layer. These steps have been found to ensure that the carbon core absorber layer can effectively allow water to pass through it over time. By treating the grille and / or the steel support layer as described above, the possibility of the carbon core absorber layer being contaminated with chemicals is eliminated, minimized, or otherwise reduced.

[0029] Figure 1 A perspective interior view of a lavatory 100 according to an example of this disclosure is shown. As mentioned above, the lavatory 100 can be on an aircraft. Alternatively, the lavatory 100 can be on various other means of transportation. In other examples, the lavatory 100 can be within a fixed structure, such as within a commercial or residential building.

[0030] The washroom 100 includes a base floor 102 supporting a toilet 104, a cabinet 106, and a sink 108. The floor 102 may include opposing supports 110 configured to securely hold dry floor components between them. Optionally, the floor 102 may be a dry floor component or otherwise include a dry floor component. Optionally, the dry floor components described herein may also be used in settings other than washrooms. For example, dry floor components can be used in kitchens, pool decks, patios, porches, and / or various other areas that may be susceptible to the effects of wet floors.

[0031] Figure 2 An exploded perspective view of a dry floor assembly 200 according to an example of the present disclosure is shown. The dry floor assembly 200 may include a vacuum layer 202 supporting a lower support layer 204. Alternatively, the dry floor assembly 200 may not include a vacuum layer 202.

[0032] The lower support layer 204 supports the intermediate core-suction layer 206. The upper layer 208 is located above the core-suction layer 206. The upper layer 208 is configured for direct engagement by a person. For example, a person stands on the upper layer 208.

[0033] The lower support layer 204, the core-absorbing layer 206, and the upper layer 208 (and optionally, the vacuum layer 202) are sandwiched together to form the dry floor assembly 200. In at least one example, the lower support layer 204, the core-absorbing layer 206, and the upper layer 208 (and optionally, the vacuum layer 202) can be housed within an outer frame, support structure, etc., such as Figure 1 The support 110 shown. For example, the lower support layer 204, the wicking layer 206, and the upper layer 208 can be combined together.

[0034] Vacuum layer 202 may include features (such as slots, channels, etc.) that can be configured to provide consistent and uniform vacuum suction when connected to a vacuum system. For example, when vacuum layer 202 is connected to an activated vacuum system, the top surface 210 of vacuum layer 202 is configured to draw liquid through lower support layer 204, wicking layer 206, and upper layer 208.

[0035] The lower support layer 204 can be a planar metal sheet. For example, the lower support layer 204 can be formed of steel. In this way, the lower support layer 204 provides a steel backing for the wicking layer 206. The lower support layer 204 may include a plurality of perforations 212 (such as holes, openings, channels, etc.) that allow liquid to be drawn through. As shown, the perforations 212 can be circular openings formed through the lower support layer 204. The perforations 212 extend from and through opposite top surfaces 214 and bottom surfaces 216 of the lower support layer 204, respectively. In at least one example, the perforations 212 can have a diameter between 0.1 inches and 0.2 inches. For example, the perforation 212 can have a diameter of 0.185 inches. Alternatively, the diameter of the perforation can be less than 0.1 inches or greater than 0.2 inches.

[0036] The wicking layer 206 is a carbon wicking layer. The carbon wicking layer provides an effective wicking layer that is also non-flammable. That is, the carbon wicking layer facilitates water distribution while also meeting non-flammability requirements (e.g., relative to vehicles such as commercial aircraft). For example, the wicking layer 206 is a carbon veil. The carbon wicking layer 206 is black, which is preferred for lavatories in various commercial aircraft, including those with black floors. In at least one example, the wicking layer 206 is or otherwise comprises carbon paper, but is not a woven product. The carbon paper is held together by an adhesive such as polyvinyl acetate (PVA), which is water-soluble. As an example, the wicking layer 206 may be 20 g / m³. 2 Carbon fiber and 5% PVA binder yarn. The wicking layer 206 provides a wicking fabric that wicks liquid in a manner similar to fabric wicking liquid.

[0037] In at least one example, the upper layer 208 is or otherwise includes a grid 222, such as a grid that may be formed of polyurethane. For example, the upper layer 208 may be formed of urethane with 10% 422 flame retardant. The grid 222 provides openings 226 therethrough. The openings 226 are configured to prevent or otherwise reduce liquid droplets on the upper layer 208.

[0038] During operation, liquid deposited on the upper layer 208 passes through opening 226. The wicking layer 206 draws the liquid from the upper layer 208 into and through the support layer 204. Optionally, an activated vacuum system can be coupled to the vacuum layer 202 and draw liquid from or within the wicking layer 206. The liquid then flows out of the dry floor assembly 200 through perforations 212 in the lower support layer 204 and through an outlet fluidly connected to the vacuum system via a conduit (e.g., hose, tube, etc.).

[0039] Figure 3 A perspective top view of a dry floor assembly 200 according to an example of this disclosure is shown. For clarity, the lower support layer 204 is shown as separate from the core layer 206, and the upper layer 208 is shown as separate from the core layer 206. As described above, the dry floor assembly 200 may or may not include a vacuum layer 202 (in... Figure 2 (as shown in the image).

[0040] Figure 4 A perspective top view of the upper layer 208 removed from tool 240 according to an example of this disclosure is shown. As noted, in at least one example, the upper layer 208 is formed of urethane. The upper layer 208 is formed and molded onto the tool, which may be a silicone tool. To ensure that the upper layer 208 is safely removed from tool 240, the upper layer 208 and / or tool 240 are coated with a release agent, for example, Frekote 1711. Alternatively, various other known release agents may be used. The upper layer 208 is then attached to the core layer 206 (in... Figure 2 and Figure 3 Before (as shown in the diagram), remove the release agent from the upper layer 208.

[0041] Figure 5A perspective top view of an upper layer 208, cleaned with methyl ethyl ketone (MEK) according to an example of this disclosure to initially remove (e.g., all, substantially all, or a portion) of the release agent. A brush 250 may be used to provide mechanical agitation to apply MEK 252 to the upper layer 208. Optionally, the upper layer 208 may be immersed in a bath of MEK 252. However, it has been found that applying MEK 252 to all portions of the upper layer 208 (including the upper and lower surfaces, side surfaces, portions between openings, etc.) using a brush 250 is effective and provides a high degree of application of MEK 252 to the upper grid 208. MEK 252 is used to remove the release agent (e.g., all, substantially all, or at least a portion of the release agent) from the grid 222 of the upper layer 208. By removing the release agent (or at least a portion thereof) from the upper layer 208 with MEK 252, the wicking layer 206 is less susceptible to contamination by the release agent.

[0042] In at least one example, the upper layer 208 can be cleaned multiple times using ME. For example, the upper layer 208 can be cleaned two or more times with MEK. Each time, a different brush can be used to apply MEK to the upper layer 208.

[0043] Figure 6 A perspective top view of the upper layer 208 of MEK, according to an example of this disclosure, after further cleaning to remove excess mold release agent and MEK 252, is shown. This is after cleaning the upper layer 208 with MEK 252 (as shown in...). Figure 5 As shown and described, the upper layer 208 is then cleaned using water 260 itself and / or detergent 262 (e.g., rinsing, scrubbing, etc.). Washing the upper layer 208 with water 260 and / or detergent 262 removes excess mold release agent and MEK from the upper layer 208. By removing any additional mold release agent and MEK from the upper layer 208, the wicking layer 206 is less susceptible to contamination.

[0044] In at least one example, a brush (same as or different from brush 250) may be used to scrub the upper layer 208 while it is being washed with water 260 and / or detergent 262. Brush 250 provides physical agitation to the washing process, which has been found to remove MEK and release agent from the upper layer 208 more effectively and efficiently. Alternatively, a brush may not be used. Instead, the upper layer 208 may be moved below a tap 264, from which water 260 flows. As another example, the upper layer 208 may be immersed in water alone or with detergent.

[0045] After the upper layer 208 has been rinsed with water 260 and detergent 262, the upper layer 208 can be further cleaned with water (e.g., rinsed) to remove any remaining detergent, MEK, and / or release agent. A brush may or may not be used during rinsing.

[0046] The upper layer 208 is cleaned with MEK, and the mold release agent is removed from the upper layer 208 by itself or by cleaning with detergent and water. Water and detergent remove MEK and any remaining mold release agent from the upper layer 208. The upper layer 208 is further rinsed with water to remove any remaining MEK, mold release agent, and detergent. Therefore, the upper layer 208 has no possibility of contaminating the core layer 206 (in Figure 2 and Figure 3 The chemical substances are shown in the diagram. After cleaning the upper layer 208 in this way, the upper layer 208 can be bonded to the wicking layer 206.

[0047] refer to Figures 2 to 6 In at least one example, the wicking layer 206 itself may be washed (or pre-washed) with water, for example, before the already cleaned upper layer 208 is bonded to the wicking layer 206. A brush may or may not be used when washing the wicking layer 206. Excess PVA is removed from the outer surface of the wicking layer 206 by washing the wicking layer 206 with water before it is bonded to the upper layer 208 and the lower support layer 204. Removal of excess PVA increases the wicking capacity of the wicking layer 206. The wicking layer 206 is dried without water or any other liquid before being bonded to the upper layer 208 and the lower support layer 204. Alternatively, the wicking layer 206 may not be washed in this manner.

[0048] Figure 7 A top view of a lower support layer 204 according to an example of this disclosure is shown. A first surface or top surface 214 of the lower support layer 204 is primed (i.e., coated with primer 215, such as a brush-applied primer or paint). The primed top surface 214 is configured to bond to the lower surface 205 of the wicking layer 206 (in... Figure 3 (as shown in the image).

[0049] Figure 8 A bottom view of the lower support layer 204 according to an example of this disclosure is shown. The second surface or bottom surface 216 (with...) Figure 7 The top surface 214 shown is not primed (e.g., bare steel without primer or paint). Reference Figure 7 and Figure 8 Only the top surface 214 (which is configured to be directly bonded to the core layer 206) is primed, while the opposite bottom surface 214 is not primed. The bottom surface 216 is configured to be directly adjacent to the underlayer, vacuum layer, floor, etc.

[0050] Bonding the primed top surface 214 to the wicking layer 206 improves adhesion and reduces the appearance of rust in the wicking layer 206 after water has been introduced into it. It has been found that leaving the opposing bottom surface 216 unprimed reduces the time required for the dry floor assembly 200 to absorb water. It has been found that when both the top surface 214 and the bottom surface 216 are primed, the wicking layer 206 stops wicking water over time. However, it has also been found that leaving the bottom surface 216 unprimed allows the wicking layer 206 to continue wicking water effectively indefinitely. Generally, rust appears to act as a protective agent for the wicking layer (e.g., on the unprimed bottom surface 216).

[0051] Optionally, the lower support layer 204 may not be used. That is, Figure 2 and Figure 3 The dry floor assembly 200 shown may not include a lower support layer 204. Instead, the upper layer 208 may be supported by a metal frame (e.g., an aluminum, steel, or titanium frame) extending, for example, along the perimeter of the upper layer 208.

[0052] Reference Figures 2 to 8 The different layers of the dry floor assembly 200 are first treated before being joined together to ensure that the carbon core layer 206 is not contaminated by chemicals that may reduce its core absorption capacity. Specifically, the upper layer 208 is washed with MEK to remove the release agent. After washing with MEK, the upper layer 208 is then washed with water itself or with detergent to remove any remaining release agent and MEK. The upper layer 208 can then be further washed (e.g., rinsed) with water to remove any remaining release agent, MEK, and / or detergent. The carbon core layer 206 can be pre-washed with water to remove excess PVA. The lower support layer 204 may be primed only on a single surface. The primed surface is the surface configured to bond to the carbon core layer 206. The opposite surface of the lower support layer 204 is unprimed.

[0053] After the upper layer 208 is washed with MEK, then with water (and optionally a detergent), and optionally further washed with water, the upper layer 208 is bonded to the carbon core layer 206, for example, to the upper surface 207 of the carbon core layer 206. The primered top surface 214 of the lower support layer 204 is bonded to the lower surface 205 of the carbon core layer 206, while the opposite bottom surface 216 is unprimed.

[0054] Figure 9 A flowchart illustrating a method for forming a dry floor assembly according to an example of this disclosure is shown. (Reference) Figures 2 to 9In step 300, the upper layer 208 is cleaned with MEK to remove the mold release agent. Step 300 may be repeated once or more as needed. Next, in step 302, the upper layer 208 is washed with water (and optionally a detergent) to remove any remaining mold release agent and MEK. Step 302 may be repeated once or more as needed. In step 304, the upper layer 208 is rinsed with water (e.g., washed) to remove any remaining mold release agent, MEK, and / or detergent. Step 304 may be repeated once or more as needed.

[0055] In step 306, the carbon core adsorbent layer 206 may be pre-washed with water, for example. Pre-washing the carbon core adsorbent layer 206 removes excess PVA from it. Alternatively, the method may omit step 306.

[0056] In step 308, the upper layer 208 (which has been washed as described herein) is then bonded to the upper surface 207 of the carbon core layer 206. In step 310, the primer-coated top surface 214 of the lower support layer 204 is bonded to the lower surface 205 of the carbon core layer 206. The bottom surface 216 is not primer-coated. That is, only the top surface 214 of the lower support layer 204 is primer-coated. Optionally, step 310 may be omitted from the method.

[0057] Figure 10 A perspective front view of an aircraft 410 according to an example of this disclosure is shown. For example, the aircraft 410 includes a propulsion system 412, which includes engines 414. Optionally, the propulsion system 412 may include more engines 414 than shown. The engines 414 are carried by wings 416 of the aircraft 410. In other examples, the engines 414 may be carried by a fuselage 418 and / or a tail 420. The tail 420 may also support a horizontal stabilizer 422 and a vertical stabilizer 424.

[0058] The fuselage 418 of the aircraft 410 defines an internal compartment 430, which includes a flight console or cockpit, one or more work areas (e.g., a galley, carry-on baggage area, etc.), one or more passenger areas (e.g., first class, business class, and second class areas), one or more lavatories, etc. (See also: Regarding...) Figures 2 to 9 The dry floor assembly 200 shown and described can be used in interior compartments 430, such as in the lavatory of an interior compartment.

[0059] Alternatively, in addition to aircraft, the examples of this disclosure can also be used with a variety of other means of transportation, such as automobiles, buses, locomotives and train carriages, ships, etc. Furthermore, the examples of this disclosure can be used relative to fixed structures, such as commercial and residential buildings.

[0060] Figure 11 A perspective top view of a dry floor assembly 200 according to an example of the present disclosure is shown. In this example, the dry floor assembly 200 includes an upper layer 208, such as a layer formed of metal, plastic, etc., fixed to a layer 209. The layer 209 is fixed to a carbon core absorption layer 206.

[0061] Figure 12 A top view of an example wicking layer 206 according to the present disclosure is shown. In this example, the wicking layer 206 includes an inner carbon wicking sheet 206a defined and supported by an outer frame 206b, for example, which may be formed of steel.

[0062] refer to Figure 9 , Figure 11 and Figure 12 Instead of steps 308 and 310, in at least one example, the method may include (after step 304 and / or step 306) bonding the upper layer 208 to the interlayer, such as interlayer 209. Next, the method may include bonding the interlayer to the upper surface of the carbon core absorber layer 206. Next, a border, such as border 206b, may be bonded to the periphery of the lower surface of the carbon core absorber layer 206 (such as around the lower surface of the carbon core absorber patch 206a).

[0063] Furthermore, this disclosure includes examples pursuant to the following terms:

[0064] Clause 1. A method of forming a dry floor assembly, the method comprising:

[0065] The upper layer is cleaned with methyl ethyl ketone (MEK) before being bonded to the carbon core absorbent layer, wherein the cleaning removes the release agent from the upper layer; and

[0066] After the cleaning process, the upper layer is bonded to the carbon core absorbent layer.

[0067] Clause 2. The method according to Clause 1, wherein the cleaning includes washing the upper layer with the MEK using one or more brushes.

[0068] Clause 3. The method according to Clause 1 or 2 further includes washing the upper layer with water or detergent after cleaning the upper layer with the MEK.

[0069] Clause 4. The method according to Clause 3, wherein washing the upper layer with one or both of the water or the detergent comprises washing the upper layer with one or more brushes using the water or the detergent.

[0070] Clause 5. The method according to Clause 3 or 4, the method further comprising rinsing the upper layer with water after cleaning the upper layer with the MEK and washing the upper layer with one or both of the water or the detergent.

[0071] Clause 6. The method according to any one of Clauses 1 to 5, the method further comprising pre-washing the carbon core layer with water prior to bonding the upper layer to the carbon core layer, wherein the pre-washing removes excess polyvinyl acetate (PVA) from the carbon core layer.

[0072] Clause 7. The method according to any one of Clauses 1 to 6, the method further comprising:

[0073] Primer is applied only to the first surface of the lower support layer, while the second surface opposite the first surface is not primed; and

[0074] The first surface of the lower support layer is bonded to the carbon core absorption layer.

[0075] Clause 8. The method according to Clause 7, wherein the lower support layer is made of steel.

[0076] Clause 9. The method according to any one of Clauses 1 to 8, wherein the upper layer comprises an urethane grid.

[0077] Clause 10. A method of forming a dry floor assembly, the method comprising:

[0078] The upper layer is cleaned with methyl ethyl ketone (MEK) before being bonded to the carbon core absorbent layer, wherein the cleaning removes the release agent from the upper layer;

[0079] After cleaning the upper layer with the MEK, wash the upper layer with water or detergent or both.

[0080] After cleaning the upper layer with the MEK and washing the upper layer with one or both of the water or the detergent, rinse the upper layer with water; and

[0081] The upper layer is bonded to the carbon core absorbent layer after the cleaning, washing, and rinsing.

[0082] Clause 11. The method according to Clause 10, wherein the cleaning includes washing the upper layer with the MEK using one or more brushes.

[0083] Clause 12. The method according to Clause 10 or 11, wherein washing the upper layer with one or both of the water or the detergent comprises washing the upper layer with one or more brushes using the water or the detergent.

[0084] Clause 13. The method according to any one of Clauses 10 to 12, the method further comprising pre-washing the carbon core layer with water prior to the bonding of the upper layer to the carbon core layer, wherein the pre-washing removes excess polyvinyl acetate from the carbon core layer.

[0085] Clause 14. The method according to any one of Clauses 10 to 13, the method further comprising:

[0086] Primer is applied only to the first surface of the lower support layer, while the second surface opposite the first surface is not primed; and

[0087] The first surface of the lower support layer is bonded to the carbon core absorption layer.

[0088] Clause 15. The method according to any one of Clauses 10 to 14, wherein the lower support layer is made of steel.

[0089] Clause 16. The method according to any one of Clauses 10 to 15, wherein the upper layer comprises an urethane grid.

[0090] Clause 17. A method of forming a dry floor assembly, the method comprising:

[0091] The upper layer is cleaned with methyl ethyl ketone (MEK) before being bonded to the carbon core absorbent layer, wherein the cleaning removes the release agent from the upper layer, and wherein the cleaning includes washing the upper layer with the MEK using one or more brushes;

[0092] After cleaning the upper layer with the MEK, the upper layer is washed with water or detergent, wherein washing the upper layer with water or detergent includes washing the upper layer with water or detergent using the one or more brushes.

[0093] After cleaning the upper layer with MEK and washing the upper layer with one or both of the water or the detergent, rinse the upper layer with water.

[0094] The carbon core absorber layer is prewashed with water before being bonded to the upper layer, wherein the prewashing removes excess polyvinyl acetate (PVA) from the carbon core absorber layer;

[0095] After the cleaning, washing, rinsing, and pre-washing, the upper layer is bonded to the carbon core absorbent layer; and

[0096] Primer is applied only to the first surface of the lower support layer, while the second surface opposite the first surface is left unprimed.

[0097] Clause 18. The method according to Clause 17, the method further comprising bonding the first surface of the lower support layer to the carbon core absorption layer.

[0098] Clause 19. The method according to Clause 18, wherein the lower support layer is made of steel.

[0099] Clause 20. The method according to Clause 19, wherein the upper layer comprises an urethane grid.

[0100] As described herein, examples of this disclosure provide methods for forming dry floor assemblies that reduce the likelihood of the wicking layer becoming contaminated with chemicals that could otherwise reduce its wicking and water permeability. Furthermore, examples of this disclosure provide dry floor assemblies that maintain the wicking layer's ability to permeate water over time.

[0101] While various spatial and directional terms such as top, bottom, lower, middle, transverse, horizontal, vertical, and front may be used to describe examples of this disclosure, it should be understood that such terms are used only with respect to the orientations shown in the accompanying drawings. These orientations may be reversed, rotated, or otherwise altered such that upper becomes lower, or vice versa, horizontal becomes vertical, etc.

[0102] As used herein, structures, constraints, or elements “configured” to perform a task or operation are formed, constructed, or adjusted in a manner corresponding to the task or operation, particularly in terms of structure. For clarity and to avoid ambiguity, objects that can only be modified to perform a task or operation are not “configured” to perform the task or operation as used herein.

[0103] It should be understood that the above description is intended to be illustrative and not restrictive. For example, the above examples (and / or aspects thereof) may be used in combination with each other. Furthermore, many modifications may be made to adapt particular situations or materials to the teachings of the various examples of this disclosure without departing from the scope of this disclosure. While the dimensions and types of materials described herein are intended to define parameters of the various examples of this disclosure, these examples are by no means restrictive but rather exemplary. Many other examples will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of the various examples of this disclosure should be determined by reference to the appended claims and the full scope of their equivalents. In the appended claims and the detailed description herein, the terms “comprising” and “wherein” are used as common English equivalents to the corresponding terms “including” and “wherein”. Furthermore, the terms “first,” “second,” and “third,” etc., are used only as designations and are not intended to impose numerical requirements on their objects.

[0104] This written description uses examples to disclose various examples of this disclosure, including best practices, and also enables any person skilled in the art to practice the various examples of this disclosure, including making and using any apparatus or system and performing any incorporated methods. The patentable scope of the various examples of this disclosure is defined by the claims, and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method of forming a dry floor assembly (200), the method comprising: The carbon core absorber layer (206) is prewashed with water (260) before the upper layer (208) is bonded to the carbon core absorber layer (206). The upper layer (208) is cleaned with methyl ethyl ketone, i.e., MEK (252), before being bonded to the carbon core absorbent layer (206), wherein the cleaning removes the release agent from the upper layer (208); Primer is applied only to the first surface of the lower support layer (204), while the second surface opposite to the first surface is not primed; as well as After the cleaning, the upper layer (208) is bonded to the carbon core absorber layer (206). The method further includes: The first surface of the lower support layer (204) is bonded to the carbon core absorption layer (206). The lower support layer (204) is formed of steel and includes a plurality of perforations (212) that allow liquid to be drawn through. The upper layer (208) includes a grid (222).

2. The method according to claim 1, wherein, The cleaning includes washing the upper layer (208) with the MEK (252) using one or more brushes (250).

3. The method according to claim 1, further comprising washing the upper layer (208) with water (260) or detergent (262) after cleaning the upper layer (208) with the MEK (252).

4. The method according to claim 3, wherein, Washing the upper layer (208) with one or both of the water (260) or the detergent (262) includes washing the upper layer (208) with one or both of the water (260) or the detergent (262) using one or more brushes (250).

5. The method according to claim 3, further comprising rinsing the upper layer (208) with water (260) after cleaning the upper layer (208) with the MEK (252) and washing the upper layer (208) with one or both of the water (260) or the detergent (262).

6. The method according to claim 1, wherein the prewashing removes excess polyvinyl acetate (PVA) from the carbon core (206).

7. The method according to claim 1, wherein, The upper layer (208) includes an urethane grid.

8. A method of forming a dry floor assembly (200), the method comprising: The carbon core absorber layer (206) is prewashed with water (260) before the upper layer (208) is bonded to the carbon core absorber layer (206). The upper layer (208) is cleaned with methyl ethyl ketone, i.e., MEK (252), before being bonded to the carbon core absorbent layer (206), wherein the cleaning removes the release agent from the upper layer (208); Primer is applied only to the first surface of the lower support layer (204), while the second surface opposite to the first surface is not primed; After cleaning the upper layer (208) with the MEK (252), the upper layer (208) is washed with one or both of water (260) or detergent (262). After cleaning the upper layer (208) with the MEK (252) and washing the upper layer (208) with one or both of the water (260) or the detergent (262), rinse the upper layer (208) with the water (260); and After the cleaning, washing and rinsing, the upper layer (208) is bonded to the carbon core layer (206). The method further includes: The first surface of the lower support layer (204) is bonded to the carbon core absorption layer (206). The lower support layer (204) is formed of steel and includes a plurality of perforations (212) that allow liquid to be drawn through. The upper layer (208) includes a grid (222).

9. The method according to claim 8, wherein, The cleaning includes washing the upper layer (208) with the MEK (252) using one or more brushes (250).

10. The method according to claim 8, wherein, Washing the upper layer (208) with one or both of the water (260) or the detergent (262) includes washing the upper layer (208) with one or both of the water (260) or the detergent (262) using one or more brushes (250).

11. The method according to claim 8, wherein the prewashing removes excess polyvinyl acetate (PVA) from the carbon core (206).

12. The method according to claim 8, wherein, The upper layer (208) includes an urethane grid.

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